Mineral wool product

ABSTRACT

A mineral wool product comprises mineral fibers bound by a binder resulting from the curing of a binder composition comprising a phenol-formaldehyde-based resin, and/or a carbohydrate containing component; a hydrophobic agent comprising (i) at least one silicone compound, such as silicone resin; (ii) at least one hardener, such as silane; (iii) optionally, at least one emulsifier; as insulation of a metallic structure, said structure having an operating temperature between 0-650° C.

REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.17/110,531, filed Dec. 3, 2020, now U.S. Pat. No. 11,519,547, issuedDec. 6, 2022, and entitled MINERAL WOOL PRODUCT PREPARED WITH A BINDERCONTAINING A HYDROPHOBIC AGENT, which is a continuation application ofU.S. application Ser. No. 15/690,964, filed Aug. 30, 2017, now U.S. Pat.No. 10,920,920, issued Feb. 16, 2021, entitled USE OF A MINERAL WOOLPRODUCT, the content of which hereby incorporated by this reference intheir entireties.

FIELD OF THE INVENTION

The present invention relates to the use of a mineral wool productcomprising mineral fibers bound by a binder resulting from the curing ofa binder composition comprising a hydrophobic agent comprising at leastone silicone compound at least one hardener and at least one emulsifier,as insulation of a metallic structure. The present invention is alsodirected to a binder composition for mineral fibers comprising such ahydrophobic agent, a mineral wool product comprising mineral fibersbound by a binder resulting from the curing of such a binder compositionand a method for producing a mineral wool product which comprises thesteps of contacting mineral fibers with such a binder composition.

BACKGROUND OF THE INVENTION

Corrosion is the deterioration of a metal as result of a chemicalreaction between it and the surrounding environment. Corrosion involvesthe conversion of the metal to a more chemically stable form, such asoxide, hydroxide or sulfide.

Corrosion of steel occurs in the presence of water and oxygen. Corrosionof steel parts is a major economic problem which often times makes up amajor part of the maintenance and renewal costs of steel structures.

A very specific problem is the problem of corrosion under insulation(CUI) which affects steel parts which are thermally isolated by aninsulating material. Steel structures are often insulated in order toavoid heat loss. Such a thermal insulation might be desirable for steelstructures which are much warmer or colder than their surroundingenvironment. CUI occurs in particular under insulation for steelstructures which undergo cyclic temperature changes like e.g. pipelinesin the oil and gas industry.

Since corrosion of steel occurs in the presence of water and oxygen, thepresence of water in contact with the steel structure is a major factorcontributing to corrosion. Since thermal insulation materialssurrounding the steel structures in order to avoid heat loss tend tokeep water in contact with the steel structure for a longer time thanthe contact would last without the surrounding insulating material, suchinsulating materials can contribute to increased corrosion. Steels arein general susceptible to CUI in the temperature range of 0° C. to 175°C. The most frequently occurring types of CUI are general and pittingcorrosion of carbon steel which may occur if wet insulation comes incontact with carbon steel, and external stress corrosion tracking (ESCT)of austenitic stainless steel, which is a specific type of corrosionmainly caused by the action of water-soluble chloride from rain water orif the insulation is not meeting the appropriate requirements. Since thecorroded surface is mostly hidden by the insulation system and will notbe observed until the insulation is removed for inspection or in theevent of metal failure leading to incidents, it is very important tocontrol CUI as much as possible.

In order to avoid CUI, the insulated steel structures are often coveredby an additional cladding which is to prevent the entering of water.However, experience shows that water often enters via fault or damagesin the cladding system or via humid air in structures which undergocyclic temperature changes. Water may also come into contact with thesteel structure internally from non-tight fittings or externally fromevents like flooding.

In order to avoid CUI, steel structures like pipelines in the oil andgas industries are often protected against corrosion by coating thesteel parts with a protective layer, e.g. with other metals like zinc oraluminum. However, such coating layers are never a completely protectinglayer and these protective measures can be extremely cost-intensive andmight be economically unacceptable for extensive pipeline systems.

There have been previous attempts to use mineral wool products asinsulation of metallic structures and still protect them from CUI. Themost common way to reduce CUI is by use of a mineral wool productprepared from a mineral wool binder to which a mineral oil has beenadded. By adding mineral oil, the water repellent requirements accordingto EN13472 can be met. However, for these mineral wool products, theinhibition of CUI is still not satisfactory, because the waterabsorption is still too high. In addition, these mineral wool productsused as insulation materials suffer from the disadvantage that whenexposed to higher temperatures, the water absorbance quickly raises tounacceptable levels. This is in particular a problem for the use of suchinsulation materials for insulating pipelines in the oil and gasindustry since in these pipelines operating temperatures often exceed150° C. Under these conditions, the water repellent properties of theseinsulation materials are quickly lost.

The problems associated with CUI can be so serious, that some companieschoose to avoid thermal insulation of pipelines even though this leadsto a highly energy-inefficient operation.

In view of the foregoing, it would be advantageous to have available aninsulation of a metallic structure that allows effective thermalinsulation of such a structure and at the same time minimizesmaintenance costs and optimizes durability of the structure.

In particular, it would be advantageous to have available an insulationof a metallic structure that allows effective thermal insulation of sucha structure and at the same time minimizes corrosion of the metallicstructure.

It would further be advantageous to have available a binder compositionfor mineral fibers which allows the production of a mineral wool productfor such purposes.

It would further be advantageous to have available a mineral woolproduct prepared with such a binder composition.

It would further be advantageous to have available a method of makingsuch a mineral wool product.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the present invention, there isprovided the use of a mineral wool product comprising mineral fibersbound by a binder resulting from the curing of a binder compositioncomprising a phenol-formaldehyde-based resin, and/or a carbohydratecontaining component, a hydrophobic agent comprising (i) at least onesilicone compound, such as silicone resin, such as a reactive siliconeresin, such as a reactive silicone resin chosen from the group ofpolyalkylethoxysiloxane, polymethylethoxysiloxane,polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane,(ii) at least one hardener, such as silane, such asalkyltriethoxysilane, such as octyltriethoxysilane, (iii) optionally, atleast one emulsifier (which preferably is present), as insulation of ametallic structure, said structure having an operating temperaturebetween 0-650° C., such as between 25-500° C., such as between 70-300°C., such as between 300-650° C.

In accordance with a second aspect of the present invention, there isprovided a binder composition for mineral fibers comprising aphenol-formaldehyde-based resin, and/or a carbohydrate-containingcomponent, and a hydrophobic agent comprising (i) at least one siliconecompound, such as silicone resin, such as a reactive silicone resin,such as a reactive silicone resin chosen from the group ofpolyalkylethoxysiloxane, polymethylethoxysiloxane,polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane,(ii) at least one hardener, such as silane, such asalkyltriethoxysilane, such as octyltriethoxysilane, (iii) optionally, atleast one emulsifier.

In accordance with a third aspect of the present invention, there isprovided a mineral wool product comprising mineral fibers bound by abinder resulting from the curing of a binder composition comprising aphenol-formaldehyde-based resin, and/or a carbohydrate-containingcomponent, a hydrophobic agent comprising (i) at least one siliconecompound, such as silicone resin, such as a reactive silicone resin,such as a reactive silicone resin chosen from the group ofpolyalkylethoxysiloxane, polymethylethoxysiloxane,polyphenyl-ethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane,(ii) at least one hardener, such as silane, such asalkyltriethoxysilane, such as octyltriethoxysilane, (iii) optionally, atleast one emulsifier.

In accordance with a fourth aspect of the present invention, there isprovided a method for producing a mineral wool product which comprisesthe steps of contacting mineral fibers with a binder compositioncomprising a phenol-formaldehyde-based resin, and/or acarbohydrate-containing component, and a hydrophobic agent comprising(i)

at least one silicone compound, such as silicone resin, such as areactive silicone resin, such as a reactive silicone resin chosen fromthe group of polyalkylethoxysiloxane, polymethylethoxysiloxane,polyphenylethoxysiloxane, polyphenyl siloxane, polyphenylmethylsiloxane,(ii) at least one hardener, such as silane, such asalkyltriethoxysilane, such as octyltriethoxysilane, (iii) optionally, atleast one emulsifier.

The present inventors have surprisingly found that a very specifichydrophobic agent or composition can impart properties to a mineral woolbinder which allow the use of a mineral wool product prepared frommineral fibers bound by such a binder as an insulation of a metallicstructure and at the same time avoid problems with corrosion underinsulation, associated with previously-known insulation products.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings,

FIG. 1 shows a mandrel pipe section in the process of beingmanufactured;

FIG. 2 illustrates a block of bonded mineral wool and a cutting stringby means of which pipe sections are cut out of the block;

FIG. 3 shows a pipe insulation in the form of a mat of mineral woolprovided with transversally extending V-grooves;

FIG. 4 illustrates in perspective view a wired mat according to theinvention where an insulation layer is provided with a chicken wire;

and

FIG. 5 shows how a wired mat according to FIG. 4 is mounted on a pipe asinsulation material.

DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

The present invention is directed to a use of a mineral wool productcomprising mineral fibers bound by a binder resulting from the curing ofa binder composition comprising a phenol-formaldehyde-based resin,and/or a carbohydrate containing component, a hydrophobic agent orcomposition comprising (i) at least one silicone compound, such assilicone resin, such as a reactive silicone resin, such as a reactivesilicone resin chosen from the group of polyalkylethox-ysiloxane,polymethylethoxysiloxane, polyphenylethoxy-siloxane,polyphenyl-siloxane, polyphenylmethylsiloxane, (ii) at least onehardener, such as silane, such as alkyltriethoxysilane, such asoctyltriethoxysilane, (iii) optionally, at least one emulsifier, asinsulation of a metallic structure, said structure having an operatingtemperature between 0-650° C., such as between 25-500° C., such asbetween 70-300° C., such as between 300-650° C.

Hydrophobic Agent

The present inventors have surprisingly found that by the use of thevery specific hydrophobic agent described herein, corrosion problems inform of corrosion under insulation can be avoided. Without wanting to bebound to any specific theory, the present inventors assume that thecorrosion problems associated with the previously-known use ofinsulation elements for metal structures are connected to the so-calledwicking-effect of such insulation products. This wicking effect of theinsulation products causes moisture, once it has entered the system, tobe retained for a prolonged period of time at the surface of the metalstructure. Accordingly, such insulation materials prolong the timeduring which the surface of the metal structure is kept in contact withwater which contributes to an increased rate of corrosion, in particularat higher temperatures

Without wanting to be bound to any specific theory the present inventorsassume that the use of the very specific hydrophobic agent describedherein allows a quicker dry out time which allows an inhibition ofcorrosion.

It has now surprisingly been found that by use of mineral wool productsprepared from a binder containing the hydrophobic agent describedherein, excellent insulation characteristics can be attained while atthe same time the corrosion under insulation is effectively inhibited.

In one embodiment, the hydrophobic agent comprises component (i) in anamount of 20 to 90 percent by weight, in particular 30 to 60 percent byweight, based on the weight of the hydrophobic agent.

In one embodiment, the hydrophobic agent comprises component (i) in formof polymethylethoxysiloxane.

In one embodiment, the hydrophobic agent comprises component (ii) in anamount of 0.5 to 10 percent by weight, in particular 1 to 5 percent byweight, based on the total weight of the hydrophobic agent.

In one embodiment, the hydrophobic agent comprises component (ii) inform of octyltriethoxysilane.

In an alternative embodiment, the silicone compound, component (i), alsoserves as the hardener component (ii) of the hydrophobic agent.Accordingly, in this alternative embodiment, the hydrophobic agentcomprises at least one silicone compound, such as silicone resin, suchas a reactive silicone resin, such as a reactive silicone resin chosenfrom the group of polyalkylethoxysiloxane, polymethylethoxysiloxane,polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane,and at least one emulsifier.

Accordingly, in one embodiment, the hardener is another compound thanthe silicone compound. In an alternative embodiment, the hardener iscomprised in the silicone compound as a curable system. In thisalternative embodiment, the hardener may be the feature that is effectedby an intra-molecular hardening of the silicone compound.

In one embodiment, the hydrophobic agent comprises (i) in an amount of30 to 60 percent by weight, (ii) in an amount of 1 to 5 percent byweight, based on the total weight of the hydrophobic agent, theremainder being (iii) and optionally other components and trace amountsof ethanol.

In one embodiment, the hydrophobic agent comprisespolymethylethoxysiloxane in an amount of 30 to 60 percent by weight,octyltriethoxysilane in an amount of 1 to 5 percent by weight, based onthe total weight of the hydrophobic agent, the remainder being (iii) andoptionally other components and trace amounts of ethanol.

In one embodiment, the binder composition comprises the hydrophobicagent in an amount of 0.05 to 2 percent by weight, such as 0.10 to 1percent by weight, such as 0.15 to 0.8 percent by weight, based on theweight of the aqueous binder composition mineral wool product.

In one embodiment, the binder composition comprises acarbohydrate-containing binder component, wherein the binder componentfurther comprises (a) a polycarboxylic acid component or any saltthereof and/or an inorganic acid or any salt thereof, and/or (b) acomponent selected from the group consisting of amine compounds,ammonia; and optionally, and/or (c) a reaction product of apolycarboxylic acid component or anhydride thereof and an alkanolaminecomponent.

In one embodiment, the mineral wool product is a pipe section or a mator wired mat.

Binder Composition

The present invention is also directed to a binder composition formineral fibers comprising: a phenol-formaldehyde-based resin, and/or acarbohydrate-containing component; and a hydrophobic agent comprising:(i) at least one silicone compound, such as silicone resin, such as areactive silicone resin, such as a reactive silicone resin chosen fromthe group of polyalkylethoxysiloxane, polymethylethoxysiloxane,polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane,(ii) at least one hardener, such as silane, such asalkyltriethoxysilane, such as octyltriethoxysilane, (iii) optionally, atleast one emulsifier (preferably, at least one emulsifier is present).

This binder composition, which comprises a specific hydrophobic agent,allows the production of mineral wool products which can be used asinsulation of a metallic structure having very good insulationcharacteristics and at the same time allows the inhibition of corrosionunder insulation.

In one embodiment, the hydrophobic agent comprises component (i) in anamount of 20 to 90 percent by weight, in particular 30 to 60 percent byweight, based on the weight of the hydrophobic agent.

In one embodiment, the hydrophobic agent comprises component (i) in formof polymethylethoxysiloxane.

In one embodiment, the hydrophobic agent comprises component (ii) in anamount of 0.5 to 10 percent by weight, in particular 1 to 5 percent byweight, based on the total weight of the hydrophobic agent.

In one embodiment, the hydrophobic agent comprises component (ii) inform of octyltriethoxysilane.

In an alternative embodiment, the silicone compound component (i) alsoserves as the hardener component (ii) of the hydrophobic agent.Accordingly, in this alternative embodiment, the hydrophobic agentcomprises at least one silicone compound, such as silicone resin, suchas a reactive silicone resin, such as a reactive silicone resin chosenfrom the group of polyalkylethoxysiloxane, polymethylethoxysiloxane,polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane,and at least one emulsifier.

Accordingly, in one embodiment, the hardener is a compound which isdifferent from the silicone compound. In an alternative embodiment, thehardener is comprised in the silicone compound as a curable system. Inthis alternative embodiment, the hardener may be the feature that iseffected by an intra-molecular hardening of the silicone compound.

In one embodiment, the hydrophobic agent comprises component (i) in anamount of 30 to 60 percent by weight, component (ii) in an amount of 1to 5 percent by weight, based on the total weight of the hydrophobicagent, the remainder being (iii) and optionally other components andtrace amounts of ethanol.

In one embodiment, the hydrophobic agent comprisespolymethylethoxysiloxane in an amount of 30 to 60 percent by weight,octyltriethoxysilane in an amount of 1 to 5 percent by weight, based onthe total weight of the hydrophobic agent, the remainder being (iii) andoptionally other components and trace amounts of ethanol.

Mineral Wool Product

The mineral fibers employed for the production of the mineral woolproducts may be any of man-made vitreous fibers (MMVF), glass fibers,ceramic fibers, basalt fibers, slag fibers, stone fibers and others.These fibers may be present as a wool product, e.g. like a stone woolproduct.

The present invention is directed to a mineral wool product comprisingmineral fibers bound by a binder resulting from the curing of a bindercomposition comprising a phenol-formaldehyde-based resin, and/or acarbohydrate-containing component, a hydrophobic agent comprising: (i)at least one silicone compound, such as silicone resin, such as areactive silicone resin, such as a reactive silicone resin chosen fromthe group of polyalkylethoxysiloxane, polymethylethoxysiloxane,polyphenyl ethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane,(ii) at least one hardener, such as silane, such asalkyltriethoxysilane, such as octyltriethoxysilane, (iii) optionally, atleast one emulsifier.

In one embodiment, the hydrophobic agent comprises component (i) in anamount of 20 to 90 percent by weight, in particular 30 to 60 percent byweight, based on the weight of the hydrophobic agent.

In one embodiment, the hydrophobic agent comprises component (i) in formof polymethylethoxysiloxane.

In one embodiment, the hydrophobic agent comprises component (ii) in anamount of 0.5 to 10 percent by weight, in particular 1 to 5 percent byweight, based on the total weight of the hydrophobic agent.

In one embodiment, the hydrophobic agent comprises (ii) in form ofoctyltriethoxysilane.

In an alternative embodiment, the silicone compound component (i) alsoserves as the hardener component (ii) of the hydrophobic agent.Accordingly, in this alternative embodiment, the hydrophobic agentcomprises at least one silicone compound, such as silicone resin, suchas a reactive silicone resin, such as a reactive silicone resin chosenfrom the group of polyalkylethoxysiloxane, polymethylethoxysiloxane,polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane,and optionally, at least one emulsifier.

Accordingly, in one embodiment, the hardener is another compound thanthe silicone compound. In an alternative embodiment, the hardener iscomprised in the silicone compound as a curable system. In thisalternative embodiment, the hardener may be the feature that is effectedby an intra-molecular hardening of the silicone compound.

In one embodiment, the hydrophobic agent comprises (i) in an amount of30 to 60 percent by weight, (ii) in an amount of 1 to 5 percent byweight, based on the total weight of the hydrophobic agent, theremainder being (iii) and optionally other components and trace amountsof ethanol.

In one embodiment, the hydrophobic agent comprisespolymethylethoxysiloxane in an amount of 30 to 60 percent by weight,octyltriethoxysilane in an amount of 1 to 5 percent by weight, based onthe total weight of the hydrophobic agent, the remainder being (iii) andoptionally other components and trace amounts of ethanol.

In one embodiment, the mineral wool product comprises the hydrophobicagent in an amount of 0.05 to 2 percent by weight, such as 0.10 to 1percent by weight, such as 0.15 to 0.8 percent by weight, based on theweight of the mineral wool product.

In one embodiment, the binder composition comprises acarbohydrate-containing binder component, wherein the binder compositionfurther comprises (a) a polycarboxylic acid component or any saltthereof and/or an inorganic acid or any salt thereof, and/or (b) acomponent selected from the group consisting of amine compounds,ammonia; and optionally, and/or (c) a reaction product of apolycarboxylic acid component or anhydride thereof and an alkanolaminecomponent.

In one embodiment the mineral wool product is in form of an insulationproduct for thermal insulation of metallic structures.

In one embodiment the mineral wool product is in form of a pipe sectionor a mat or wired mat.

Pipe sections are pre-formed (formed in the factory) insulationmaterials used for the insulation around pipes.

A typical embodiment of such a pipe section is a mandrel wound pipesection.

A mandrel wound pipe section is a pre-formed, full-round cylindricalpipe insulation product which is produced by wrapping an uncured mineralwool blanket around a mandrel in spiral manner for forming andsubsequent curing. The cylindrical pipe sections are split and hingedfor easy snap-on assembly. Mandrel wound pipe sections can be both facedand un-faced with aluminum foil.

FIG. 1 shows how such a mandrel wound pipe section is typicallyproduced. In this method the pipe section is wound from a thin web 9 ofmineral wool, preferably stone wool. The web 9 is wound around aperforated mandrel 10 as it is known when producing wound pipe sections.After winding hot air is conventionally blown from inside the mandreland through the wound pipe section for curing of the thermoset binder.

An alternative embodiment of a pre-formed pipe section is shown in FIG.2 .

FIG. 2 illustrates a block (1) of bonded mineral wool and a cuttingstring (4) by means of which pipe sections (5) having atongue/groove-joint (6) and a T-shaped hinge slit (7) are cut out of theblock in the transverse direction of the block and parallel to the mainsurface planes of the block. After cutting out each pipe section 5 isremoved from the block.

A further embodiment of a pipe insulation is shown in FIG. 3 which showsa mat of mineral wool provided with transversally extending V-grooves.Due to the V-grooves the mat can be wrapped around a pipe on site asindicated in the version shown at the front in FIG. 3 .

An alternative embodiment is a mineral wool product in form of a wiredmat. FIG. 4 is an illustration of such a wired mat.

FIG. 4 illustrates in perspective view such a wired mat according to theinvention where an insulation layer 1 in terms of a mineral fiber web isprovided with a chicken wire 3 which is fastened to the insulating layer1 by means of an iron thread 14 stitched through the insulating layer. Afixation means 2 in terms of a galvanized iron wire may be in zigzagconfiguration and placed under the chicken wire 3. In an alternativeembodiment, no such fixation means are included.

In a further alternative embodiment, mats are used without any wiring.In this alternative embodiment, the mineral wool product is in form of amineral wool mat—sometimes also called a slab.

FIG. 5 shows how a wired mat according to FIG. 4 is mounted on a pipe asinsulation material.

FIG. 5 illustrates an embodiment of the insulating product according tothe invention mounted on a pipe 16, where the product comprisinginsulating layer 1 is adapted to fit the circumference of pipe 16 andfixation means 5 a and 5 b extending around the mounted product securesthe product on the pipe 16 by knots 15 a and 15 b. The fixation means 5c has not yet been extended to protrude beyond the adjoining endsurfaces of the product to enable the fixation thereby.

In one embodiment the mineral wool product has a water absorptionaccording to ASTM C1763-16 of less than 4.0 vol. %, such as less than2.0 vol. %, such as less than 1.5 vol. %.

In one embodiment the mineral wool product has a water absorptionaccording to EN13472 of less than 1.0 kg/m2, such as less than 0.8kg/m2, such as less than 0.5 kg/m2, such as less than 0.3 kg/m2.

In one embodiment the mineral wool product has water absorptionaccording to EN13472 of less than 1.0 kg/m2, such as less than 0.8kg/m2, such as less than 0.5 kg/m2, such as less than 0.3 kg/m2,following storage of the mineral wool product at 250° C. for 24 hours.

In this embodiment, in which the water absorption according to EN13472is measured following storage of the mineral wool product at 250° C. for24 hours, the following protocol for exposing the product to 250° C. for24 hours is followed:

-   -   Pre-heat a laboratory furnace to 250° C. which is placed under a        fume hood.    -   Place the samples in the furnace for a period of 24 hours.    -   The ventilation of the furnace shall be off, except from the        last 30 minutes of the heating when the ventilation shall be on        in order to remove fumes from the furnace in a safe way.    -   Remove the samples from the furnace and let them cool down to        ambient temperature.    -   After that proceed with the requested test program for water        absorption.

In one embodiment, the mineral wool product according to the presentinvention has a density of 20 to 150 kg/m3, such as 40 to 130 kg/m3,such as 60-120 kg/m3.

Method for Producing a Mineral Wool Product

The present invention is also directed to a method for producing amineral wool product which comprises the steps of contacting mineralfibers with a binder composition comprising a phenol-formaldehyde-basedresin, and/or a carbohydrate-containing component, and a hydrophobicagent comprising (i) at least one silicone compound, such as siliconeresin, such as a reactive silicone resin, such as a reactive siliconeresin chosen from the group of polyalkylethoxysiloxane,polymethylethoxysiloxane, polyphenylethoxysiloxane, polyphenylsiloxane,polyphenylmethylsiloxane, (ii) at least one hardener, such as silane,such as alkyltriethoxysilane, such as octyltriethoxysilane, (iii) atleast one emulsifier.

In one embodiment, the hydrophobic agent comprises component (i) in anamount of 20 to 90 percent by weight, in particular 30 to 60 percent byweight, based on the weight of the hydrophobic agent.

In one embodiment, the hydrophobic agent comprises component (i) in formof polymethylethoxysiloxane.

In one embodiment, the hydrophobic agent comprises component (ii) in anamount of 0.5 to 10 percent by weight, in particular 1 to 5 percent byweight, based on the total weight of the hydrophobic agent.

In one embodiment, the hydrophobic agent comprises component (ii) inform of octyltriethoxysilane.

In an alternative embodiment, the silicone compound component (i) alsoserves as the hardener component (ii) of the hydrophobic agent.Accordingly, in this alternative embodiment, the hydrophobic agentcomprises at least one silicone compound, such as silicone resin, suchas a reactive silicone resin, such as a reactive silicone resin chosenfrom the group of polyalkylethoxysiloxane, polymethylethoxysiloxane,polyphenylethoxysiloxane, polyphenylsiloxane, polyphenylmethylsiloxane,and at least one emulsifier.

Accordingly, in one embodiment, the hardener is another compound thanthe silicone compound. In an alternative embodiment, the hardener iscomprised in the silicone compound as a curable system. In thisalternative embodiment, the hardener may be the feature that is effectedby an intra-molecular hardening of the silicone compound.

In one embodiment, the hydrophobic agent comprises (i) in an amount of30 to 60 percent by weight, (ii) in an amount of 1 to 5 percent byweight, based on the total weight of the hydrophobic agent, theremainder being (iii) and optionally other components and trace amountsof ethanol.

In one embodiment, the hydrophobic agent comprisespolymethylethoxysiloxane in an amount of 30 to 60 percent by weight,octyltriethoxysilane in an amount of 1 to 5 percent by weight, based onthe total weight of the hydrophobic agent, the remainder being (iii) andoptionally other components and trace amounts of ethanol.

In one embodiment, the mineral wool product comprises the hydrophobicagent in an amount of 0.05 to 2 percent by weight, such as 0.10 to 1percent by weight, such as 0.15 to 0.8 percent by weight, based on theweight of the mineral wool product.

In one embodiment, the binder composition comprises acarbohydrate-containing binder component, wherein the binder compositionfurther comprises (a) a polycarboxylic acid component or any saltthereof and/or an inorganic acid or any salt thereof, and/or (b) acomponent selected from the group of amine compounds, ammonia, andoptionally, and/or (c) a reaction product of a polycarboxylic acidcomponent or anhydride thereof and an alkanolamine component.

In one embodiment the method is a method for producing a mineral woolproduct in form of an insulation product for thermal insulation ofmetallic surfaces structures.

In one embodiment the method is a method for producing a mineral woolproduct in form of a pipe section or a mat or wired mat.

To sum up, the present invention provides the following items:

-   1 The use of a mineral wool product comprising mineral fibers bound    by a binder resulting from the curing of a binder composition    comprising    -   a phenol-formaldehyde-based resin, and/or a carbohydrate        containing component;    -   a hydrophobic agent comprising:    -   (i) at least one silicone compound, such as silicone resin, such        as a reactive silicone resin, such as a reactive silicone resin        chosen from the group of polyalkylethoxysiloxane,        polymethylethoxysiloxane, polyphenylethoxysiloxane,        polyphenylsiloxane, polyphenylmethylsiloxane;    -   (ii) at least one hardener, such as silane, such as        alkyltriethoxysilane, such as octyltriethoxysilane;    -   (iii) optionally, at least one emulsifier;    -   as insulation of a metallic structure, said structure having an        operating temperature between 0-650° C., such as between 25-500°        C., such as between 70-300° C., such as between 300-650° C.-   2. The use according to item 1, wherein the hydrophobic agent    comprises (i) in an amount of 20 to 90 percent by weight, in    particular 30 to 60 percent by weight, based on the weight of the    hydrophobic agent.-   3. The use according to item 1 or 2, wherein the hydrophobic agent    comprises (ii) in an amount of 0.5 to 10 percent by weight, in    particular 1 to 5 percent by weight, based on the total weight of    the hydrophobic agent.-   4. The use according to any one of the preceding items, wherein the    hydrophobic agent comprises (i) in an amount of 30 to 60 percent by    weight, (ii) in an amount of 1 to 5 percent by weight, based on the    total weight of the hydrophobic agent, the remainder being (iii) and    optionally other components and trace amounts of ethanol.-   5. The use according to any one of the preceding items, wherein the    hydrophobic agent comprises polymethylethoxysiloxane in an amount of    30 to 60 percent by weight, octyltriethoxysilane in an amount of 1    to 5 percent by weight, based on the total weight of the hydrophobic    agent, the remainder being (iii) and optionally other components and    trace amounts of ethanol.-   6. The use according to any one of the preceding items, wherein the    mineral wool product comprises the hydrophobic agent in an amount of    0.05 to 2 percent by weight, such as 0.10 to 1 percent by weight,    such as 0.15 to 0.8 percent by weight, based on the weight of the    mineral wool product.-   7 The use according to any one of the preceding items, wherein the    binder composition comprises a carbohydrate-containing binder    component, wherein the binder composition further comprises    -   (a) a polycarboxylic acid component or any salt thereof and/or        an inorganic acid or any salt thereof, and/or    -   (b) a component selected from the group consisting of amine        compounds, ammonia; and optionally, and/or    -   (c) a reaction product of a polycarboxylic acid component or        anhydride thereof and an alkanolamine component.-   8. The use according to any one of the preceding items, wherein the    mineral wool product is a pipe section or a mat or wired mat.-   9. A binder composition for mineral fibers comprising:    -   a phenol-formaldehyde-based resin, and/or a        carbohydrate-containing component; and    -   a hydrophobic agent comprising:        -   (i) at least one silicone compound, such as silicone resin,            such as a reactive silicone resin, such as a reactive            silicone resin chosen from the group of            polyalkylethoxysiloxane, polymethylethoxysiloxane,            polyphenylethoxysiloxane, polyphenylsiloxane,            polyphenylmethylsiloxane;        -   (ii) at least one hardener, such as silane, such as            alkyltriethoxysilane, such as octyltriethoxysilane;        -   (iii) optionally, at least one emulsifier.-   10. The binder composition according to item 9, wherein the    hydrophobic agent comprises (i) in an amount of 20 to 90 percent by    weight, in particular 30 to 60 percent by weight, based on the    weight of the hydrophobic agent.-   11. The binder composition according to item 9 or 10, wherein the    hydrophobic agent comprises (ii) in an amount of 0.5 to 10 percent    by weight, in particular 1 to 5 percent by weight, based on the    total weight of the hydrophobic agent.-   12. The binder composition according to any one of items 9 to 11,    wherein the hydrophobic agent comprises (i) in an amount of 30 to 60    percent by weight, (ii) in an amount of 1 to 5 percent by weight,    based on the total weight of the hydrophobic agent, the remainder    being (iii) and optionally other components and trace amounts of    ethanol.-   13. The binder composition according to any one of the items 9 to    12, wherein the hydrophobic agent comprises polymethylethoxysiloxane    in an amount of 30 to 60 percent by weight, octyltriethoxysilane in    an amount of 1 to 5 percent by weight, based on the total weight of    the hydrophobic agent, the remainder being (iii) and optionally    other components and trace amounts of ethanol.-   14. The binder composition according to any one of the items 9 to    13, wherein the binder composition comprises a    carbohydrate-containing binder component, wherein the binder    composition further comprises    -   (a) a polycarboxylic acid component or any salt thereof and/or        an inorganic acid or any salt thereof, and/or    -   (b) a component selected from the group consisting of amine        compounds, ammonia; and optionally, and/or    -   (c) a reaction product of a polycarboxylic acid component or        anhydride thereof and an alkanolamine component.-   15. A mineral wool product comprising mineral fibers bound by a    binder resulting from the curing of a binder composition comprising    -   a phenol-formaldehyde-based resin, and/or a        carbohydrate-containing component;    -   a hydrophobic agent comprising:    -   (i) at least one silicone compound, such as silicone resin, such        as a reactive silicone resin, such as a reactive silicone resin        chosen from the group of polyalkylethoxysiloxane,        polymethylethoxysiloxane, polyphenylethoxysiloxane,        polyphenylsiloxane, polyphenylmethylsiloxane;    -   (ii) at least one hardener, such as silane, such as        alkyltriethoxysilane, such as octyltriethoxysilane;    -   (iii) optionally, at least one emulsifier.-   16. The mineral wool product according to item 15, wherein the    hydrophobic agent comprises (i) in an amount of 20 to 90 percent by    weight, in particular 30 to 60 percent by weight, based on the    weight of the hydrophobic agent.-   17. The mineral wool product according to item 15 or 16, wherein the    hydrophobic agent comprises (ii) in an amount of 0.5 to 10 percent    by weight, in particular 1 to 5 percent by weight, based on the    total weight of the hydrophobic agent.-   18. The mineral wool product according to any one of items 15 to 17,    wherein the hydrophobic agent comprises (i) in an amount of 30 to 60    percent by weight, (ii) in an amount of 1 to 5 percent by weight,    based on the total weight of the hydrophobic agent, the remainder    being (iii) and optionally other components and trace amounts of    ethanol.-   19. The mineral wool product according to any one of items 15 to 18,    wherein the hydrophobic agent comprises polymethylethoxysiloxane in    an amount of 30 to 60 percent by weight, octyltriethoxysilane in an    amount of 1 to 5 percent by weight, based on the total weight of the    hydrophobic agent, the remainder being (iii) and optionally other    components and trace amounts of ethanol.-   20. The mineral wool product according to any one of items 15 to 19,    wherein the mineral wool product comprises the hydrophobic agent in    an amount of 0.05 to 2 percent by weight, such as 0.10 to 1 percent    by weight, such as 0.15 to 0.8 percent by weight, based on the    weight of the mineral wool product.-   21. The mineral wool product according to any one of items 15 to 20,    wherein the binder composition comprises a carbohydrate-containing    binder component, wherein the binder composition further comprises    -   (a) a polycarboxylic acid component or any salt thereof and/or        an inorganic acid or any salt thereof, and/or    -   (b) a component selected from the group consisting of amine        compounds, ammonia; and optionally, and/or    -   (c) a reaction product of a polycarboxylic acid component or        anhydride thereof and an alkanolamine component.-   22. The mineral wool product according to any one of items 15 to 21,    in the form of an insulation product for thermal insulation of    metallic structures.-   23. The mineral wool product according to any one of items 15 to 22,    in the form of a pipe section or a mat or wired mat.-   24. The mineral wool product according to any one of items 15 to 23,    having a water absorption according to ASTM C1763-16 of less than    4.0 vol. %, such as less than 2.0 vol. %, such as less than 1.5 vol.    %.-   25. The mineral wool product according to any one of items 15 to 24,    having a water absorption according to EN13472 of less than 0.5    kg/m², such as less than 0.3 kg/m².-   26. The mineral wool product according to any one of items 15 to 25,    having a water absorption according to EN13472 of less than 1.0    kg/m², such as less than 0.8 kg/m², such as less than 0.5 kg/m²,    such as less than 0.3 kg/m², following storage of the mineral wool    product at 250° C. for 24 hours.-   27. A method for producing a mineral wool product which comprises    the steps of contacting mineral fibers with a binder composition    comprising    -   a phenol-formaldehyde-based resin, and/or a        carbohydrate-containing component; and    -   a hydrophobic agent comprising:    -   (i) at least one silicone compound, such as silicone resin, such        as a reactive silicone resin, such as a reactive silicone resin        chosen from the group of polyalkylethoxysiloxane,        polymethylethoxysiloxane, polyphenylethoxysiloxane,        polyphenylsiloxane, polyphenylmethylsiloxane;    -   (ii) at least one hardener, such as silane, such as        alkyltriethoxysilane, such as octyltriethoxysilane;    -   (iii) optionally, at least one emulsifier.-   28. The method for producing a mineral wool product according to    item 27, wherein the hydrophobic agent comprises (i) in an amount of    20 to 90 percent by weight, in particular 30 to 60 percent by    weight, based on the weight of the hydrophobic agent.-   29. The method for producing a mineral wool product according to    item 27 or 28, wherein the hydrophobic agent comprises (ii) in an    amount of 0.5 to 10 percent by weight, in particular 1 to 5 percent    by weight, based on the total weight of the hydrophobic agent.-   30. The method for producing a mineral wool product according to any    one of items 27 to 29, wherein the hydrophobic agent comprises (i)    in an amount of 30 to 60 percent by weight, (ii) in an amount of 1    to 5 percent by weight, based on the total weight of the hydrophobic    agent, the remainder being (iii) and optionally other components and    trace amounts of ethanol.-   31. The method for producing a mineral wool product according to any    one of items 27 to 30, wherein the hydrophobic agent comprises    polymethylethoxysiloxane in an amount of 30 to 60 percent by weight,    octyltriethoxysilane in an amount of 1 to 5 percent by weight, based    on the total weight of the hydrophobic agent, the remainder    being (iii) and optionally other components and trace amounts of    ethanol.-   32. The method for producing a mineral wool product according to any    one of items 27 to 31, wherein the mineral wool product comprises    the hydrophobic agent in an amount of 0.05 to 2 percent by weight,    such as 0.10 to 1 percent by weight, such as 0.15 to 0.8 percent by    weight, based on the weight of the mineral wool product.-   33. The method for producing a mineral wool product according to any    one of items 27 to 32, wherein the binder composition comprises a    carbohydrate-containing binder component, wherein the binder    composition further comprises    -   (a) a polycarboxylic acid component or any salt thereof and/or        an inorganic acid or any salt thereof, and/or    -   (b) a component selected from the group consisting of amine        compounds, ammonia; and optionally, and/or    -   (c) a reaction product of a polycarboxylic acid component or        anhydride thereof and an alkanolamine component.-   34. The method for producing a mineral wool product according to any    one of items 27 to 33, in form of an insulation product for thermal    insulation of metallic structures.-   35. The method for producing a mineral wool product according to any    of items 27 to 34, in form of a pipe section or a mat or wired mat.

The present invention is further illustrated by the following examples:

Examples

Different insulation products were tested with regard to waterabsorption properties according to the standard ASTM C1763-16 testmethod.

The results of tests are stated in Table 1 below. In Table 1, Roxul® isstone wool insulation, Roxul® SL960 is a stone wool insulation board,and Roxul® PS980 is a stone wool, mandrel would pipe section.

TABLE 1 Mass, after Mass, Mass, immersion recondition Water Abs.Recovery Recovery Density Volume initial (2 hr) (after 48 hr) (WA) WA, 2hr WA, 48 hr Sample kg/m³ cm³ g g g vol. % vol. % vol. % Roxul ® SL960,mat 92 4532 415.69 658.47 415.82 5.4 4.9 0.003 E-glass, pipe section 2342755 646.09 3166.03 2599.29 22.9 22.6 17.73 Roxul ®, Pipe section 732162 158.14 183.88 158.93 1.2 0.5 0.037 with SILRES ® BS45 Mineral wool,pipe 145 2427 350.88 832.86 438.04 5.0 4.8 0.898 section Roxul ® PS980,pipe 183 1776 325.90 806.37 556.76 6.8 6.6 3.249 section Mineral wool,mat 80 7582 606.86 2040.20 1269.98 18.9 18.2 8.746

Pipe sections were tested with regard to water absorption propertiesaccording to the standard EN13472. The pipe sections were manufacturedas a mandrel wound pipe section and are from the ProRox product seriesand the tested specimen had a thickness of 50 mm.

The tests were done on both untreated products and products that wereaged (250° C./24 h).

SILRES® BS 45 silicon resin from Wacker had been added to the productsin amount of 0.41 wt. %.

The results from a triple-determination are stated in Table 2. ProRox®960 is a stone wool pipe section.

TABLE 2 Roxul ® 183 1776 325.90 806.37 556.75 6.8 6.6 3.249 PS980, pipesection Mineral 80 7582 606.86 2040.20 1269.98 18.9 18.2 8.746 wool, mat

The entire disclosures of European patent applications 17188636.9 and17188632.8, both filed on Aug. 30, 2017, ae expressly incorporated byreference herein.

That which is claimed is:
 1. A mineral wool product comprising mineralfibers bound by a binder resulting from a curing of a binder compositionfor mineral fibers, wherein the binder composition comprises: aphenol-formaldehyde-based resin; and a hydrophobic agent comprising: asilicone compound, and a silane or an emulsifier; wherein thehydrophobic agent is present at approximately 0.05 to 2 percent byweight of the mineral wool insulation product; wherein the mineral woolproduct has a water absorption according to ASTM C1763-16 of less than4.0 vol. percent, and/or following storage of the mineral wool productat 250 degrees centigrade for 24 hours, the mineral wool product has awater absorption according to EN13472 of less than 1.0 kg/m²; andwherein the mineral wool product has a density of 20 kg/m³ to 150 kg/m³.2. The mineral wool product of claim 1, wherein the hydrophobic agent isin an amount of 0.1 to 1 percent by weight, based on a total weight ofthe mineral wool product.
 3. The mineral wool product of claim 1,wherein the hydrophobic agent is in an amount of 0.15 to 0.8 percent byweight, based on a total weight of the mineral wool product.
 4. Themineral wool product of claim 1, wherein the silicone compound comprisessilicone resin.
 5. The mineral wool product of claim 4, wherein thesilicone resin comprises at least one of polyalkylethoxysiloxane,polyphenylethoxysiloxane, polyphenylsiloxane, orpolyphenylmethylsiloxane.
 6. The mineral wool product of claim 1,wherein the silane comprises an alkyltriethoxysilane.
 7. The mineralwool product of claim 1, wherein the binder composition furthercomprises a carbohydrate-containing component and a polycarboxylic acidcomponent.
 8. The mineral wool product of claim 1, wherein the bindercomposition further comprises a carbohydrate-containing component and atleast one of ammonia or an amine compound.
 9. The mineral wool productof claim 1, wherein the binder composition further comprises acarbohydrate-containing component and a reaction product ofpolycarboxylic acid anhydride and an alkanolamine component.
 10. Themineral wool product of claim 1, wherein the mineral wool product has adensity in a range of 40 kg/m³ to 130 kg/m³.
 11. The mineral woolproduct of claim 1, wherein the mineral wool product is at least one ofa pipe section, a mat, or a wired mat.
 12. The mineral wool product ofclaim 1, wherein, following storage of the mineral wool product at 250degrees centigrade for 24 hours, the water absorption of the mineralwool product according to EN13472 is less than 0.5 kg/m².
 13. Themineral wool product of claim 1, wherein, following storage of themineral wool product at 250 degrees centigrade for 24 hours, the waterabsorption of the mineral wool product according to EN13472 is less than0.3 kg/m².
 14. The mineral wool product of claim 1, wherein the mineralwool product has a density in a range of 60 kg/m³ to 120 kg/m³.
 15. Amineral wool insulation product comprising: mineral fibers; a curedbinder composition comprising a phenol-formaldehyde-based resin, whereinthe cured binder composition binds the mineral fibers; and a hydrophobicagent comprising a silicone compound and a hardener and/or anemulsifier, wherein the hydrophobic agent is present at approximately0.1 to 1 percent by weight of the mineral wool insulation product;wherein the mineral wool product has a water absorption according toASTM C1763-16 of less than 4.0 vol. percent and/or a water absorptionaccording to EN13472 of less than 1.0 kg/m² following storage of themineral wool product at 250 degrees centigrade for 24 hours; and whereinthe mineral wool product has a density of 20 kg/m³ to 150 kg/m³.
 16. Themineral wool product of claim 15, wherein the hydrophobic agent is in anamount of 0.1 to 1 percent by weight, based on a total weight of themineral wool product.
 17. The mineral wool product of claim 15, whereinthe hydrophobic agent is in an amount of 0.15 to 0.8 percent by weight,based on a total weight of the mineral wool product.
 18. The mineralwool product of claim 15, wherein the silicone compound comprisessilicone resin.
 19. The mineral wool product of claim 15, wherein themineral wool product has a density in a range of 40 kg/m³ to 130 kg/m³.20. The mineral wool product of claim 15, wherein the mineral woolproduct has a density in a range of 60 kg/m³ to 120 kg/m³.